Insert for insulated concrete forms

ABSTRACT

An insert is provided for an ICF which increases the insulation provided by the ICF. This adapts the ICF for use in buildings subject to harsher environments. The insert may have a protuberanced face which abuts an inner face of one of the ICF panels. The protuberances may be configured so that water penetrating the wall of ICFs is channeled down and out of the wall.

BACKGROUND

This invention relates to an insert for an insulated concrete form (ICF) and to an ICF with an insert.

ICFs are used in the construction of buildings. An ICF typically has a pair of opposed expanded foam panels joined by ties, where each tie terminates at either end in a head embedded in one of the panels. The top and bottom walls of the opposed panels of an ICF may have features that allow the ICF to be interlocked with ICFs above and below it. In use, ICFs are stacked to form walls. Concrete may then be poured into the cavity between the opposed panels of the stacked ICFs. An exterior finish may be applied directly to the outer face of the wall and drywall, or another wall finishing material, may be joined to the inner face of the wall. In this regard, the embedded heads of the ties of the ICFs may be configured so that they give a purchase to fasteners used to join the wall finishing material to the ICFs.

It may be apparent that ICFs save considerable labour in constructing a building as compared with a more traditional approach of setting up a wall form, pouring concrete into the form, removing the form, constructing a frame for the resulting concrete wall, adding insulation and affixing wall finishings to the frame.

Despite these advantages, because ICFs are mass produced, they may not be suited to all climates. Further, with ICFs, it may be costly to provide for drainage. In this regard, when applying a stucco finish on a wall formed of ICFs, it is known to first adhere a layer of rectangular foam blocks to the exterior of the ICF wall which blocks have grooves or channels along their back face to provide drainage. The stucco is applied to the front face of these blocks. This approach is time consuming and adds significantly to the cost of the construction project. Therefore, there is a need for improvements.

SUMMARY

An insert is provided for an ICF which increases the insulation provided by the ICF. This adapts the ICF for use in buildings subject to harsher environments. The insert may have a face with low relief protuberances and this face may abut an inner face of one of the ICF panels. The protuberances may be configured to assist in channeling water penetrating the wall of ICFs down and out of the wall.

According to an embodiment, there is provided an insert for an insulated concrete form, comprising an expanded foam panel having a plurality of parallel slots extending from a bottom wall of said panel toward a top wall of said panel, each slot extending to a front face of said panel and to a back face of said panel, each slot extending a majority of a distance between said bottom wall and said top wall of said panel, said slots spaced and sized to receive ties between opposed panels of an insulated concrete form such that said panel may be inserted between said opposed panels.

In another aspect, there is provided an insulated concrete form comprising an expanded foam first panel; an expanded foam second panel opposite said first panel; a plurality of ties extending between said first panel and said second panel, each tie having a first head embedded in said first panel and a second head embedded in said second panel; an expanded foam insert panel having a plurality of parallel slots extending from a bottom wall of said insert panel toward a top wall of said insert panel, each slot extending to a front face of said insert panel and to a back face of said insert panel, each slot extending a majority of a distance between said bottom wall and said top wall of said insert panel, said insert panel inserted between said first panel and said second panel with each slot of said insert panel receiving one of said ties and a front face of said insert panel lying adjacent an inside face of said first panel.

Other features and advantages will become apparent from the following description in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings which illustrate example embodiments,

FIG. 1 is a partially cut away perspective view of a known ICF,

FIG. 2 is a front perspective view of an example insert for an ICF, such as the ICF of FIG. 1,

FIG. 3 is a front view of the insert of FIG. 2,

FIG. 4 is a rear perspective view of the insert of FIG. 2,

FIG. 5 is a partially cut away rear perspective view of the insert of FIG. 2 installed in the ICF of FIG. 1,

FIG. 6 is a partially cut away front perspective view of FIG. 5,

FIGS. 7A and 7B are each a schematic view of a portion of a wall of ICFs constructed using the inserts of FIG. 2,

FIG. 8 is a front perspective view of another example insert for an ICF,

FIG. 9 is a rear perspective view of the insert of FIG. 9,

FIG. 10 is a front view of the insert of FIG. 8,

FIG. 11 is a front perspective view of another example an insert for an ICF,

FIG. 12 is a rear perspective view of the insert of FIG. 11, and

FIG. 13 is a front view of the insert of FIG. 11.

DESCRIPTION

Turning to FIG. 1, an ICF 50 has a first expanded foam panel 52 and a second expanded foam panel 54 joined in spaced relation by ties 56. Panel 52 has an inside wall 57. Each tie 56 has a central web portion 58 and terminates at either end in a head 60. The head 60 at one end of each tie is embedded in the first panel 52 and the head 60 at the opposite end of each tie is embedded in the second panel 54. A plurality of buttons 62 project above the top wall 61 of the panels 52, 54. Buttons 62 can interlock with recesses (not shown) of a like ICF stacked on ICF 50.

Turning to FIGS. 2 and 3, an insert panel 100 that may be used with ICF 50 is fabricated of expanded foam and has a plurality of parallel slots 110 extending from a bottom wall 112 of the panel toward a top wall 114 of the panel. Each slot extends completely through the panel: from the front face 116 of the panel to the back face 118 of the panel. Each slot has a lengthwise extent, L, which extends the majority of the distance, D, between the bottom and top walls of the panel.

The top wall 114 of the panel has a chamfered edge 115 at the front face 116 of the panel.

The front face 116 of the panel has a series of low relief protuberances 120 that extend from the bottom wall 112 to the top wall 114 of the insert panel 100. Each slot 110 extends along one protuberance 120 partially bisecting the protuberance. Each protuberance is shaped as an upper substantially circular portion 122 extending from top wall 114 and a lower substantially circular portion 124 extending from bottom wall 112, joined by a narrow neck 126. In view of the shape of the protuberances, it will be apparent that each protuberance, proximate top wall 114, is radiused.

The length and width of the insert panel 100 is chosen to match the length and width of the panels of the ICF with which the insert is designed to be used. The width of the slots 110 is chosen so that the slots will fit over the webs of the ties of the ICF with which the insert is designed to be used. The insert panel 100 may have a thickness at the protuberances of about 2″ (about 5 cm), with the protuberances 120 standing proud of the balance of the front face 116 of the insert panel by about 0.4″ (about 1 cm), although other dimensions may be chosen as required.

With reference to FIG. 4, the back face 118 of insert 100 is free of protuberances and, indeed, apart from slots 110, is featureless.

In use, referencing FIGS. 5 and 6, insert 100 is inserted between the panels 52, 54 of the ICF 50 against the inside face 57 (FIG. 1) of panel 52 of the ICF so that the slots 110 of the insert receive the webs 58 of the ties 56 of the ICF. The insert is pushed down until its top wall 112 aligns with the top wall 61 of panel 62, as shown in FIG. 5. In this regard, the length of the slots 110 of the insert 100 is chosen so as to allow the insert to be pushed down to this extent.

Because of the protuberances 120 on the front face 116 of the insert, with the insert against the inside face 57 of panel 52, the non-protuberanced portions of the front face 116 of the insert stand off from the inside face 57 of the ICF panel 52.

ICFs 50 with inserts 100 may be used in constructing a building in substantially the same manner as with known ICFs. However, the ICFs with inserts should be oriented so that panel 52 of each ICF, against which the insert 100 lies, is the outside panel of the ICF. With this orientation, as will be explained, the ICFs with inserts can reduce the prospect of water damage.

ICFs 50 with insert panels 100 may be stacked to form a wall 130. FIG. 7A illustrates an example wall 130 with a window frame 132 and insert panels 100 a, 100 b, and 100 c. Even once wall 130 is finished, this frame provides a point of ingress for water from the outside. However, should water penetrate below the window frame 132 past the outer panel of the ICF containing insert 100 a, as illustrated by water path W, this water will be channeled downwardly in the spaces formed between the protuberances 120 of the insert 100 a of the ICF to the insert 100 b of the ICF directly below, and so on, to the bottom of the wall where a gap may be provided to allow the water to leave the wall. In this regard, the chamfered edge 115 of the top wall of each insert panel 100 assists in ensuring water does not become trapped in the joints between panels. To further assist in this regard, optionally, the bottom wall of each insert panel may also have a chamfered edge (not shown).

There may be situations where the protuberances of one course of the wall are not aligned with the protuberances of the next course of the wall. However, because the protuberances, proximate the top wall of each insert, are radiused, even with mis-aligned protuberances, the inserts will channel water to the bottom of the wall. This is illustrated in FIG. 7B where water from window frame 132′ of wall 130′ is, channeled along path W′ down insert 100 d and insert 100 e, despite the mis-alignment of the protuberances between these two inserts.

By channeling water out of the ICF, the inserts reduce the prospect of water being retained within the wall and possibly damaging the wall through repeated freezing and melting cycles.

FIGS. 8 to 10 illustrate a second embodiment for the inserts. Turning to FIGS. 8 to 10, like insert 100 of FIGS. 2 to 4, insert 200 has a plurality of parallel slots 210 extending from a bottom wall 212 of the panel toward a top wall 214 of the panel. However, the protuberances 220 on the front face 216 of insert 200 have a different shape: they are long narrow rectangles extending from the bottom wall 212 to the top wall 214 of the insert panel 200. As with insert panel 100, each slot 110 extends along one protuberance 220 partially bisecting the protuberance. The back face 218 of insert 200 is indistinguishable from the back face of insert 100.

Insert 200 functions in the same manner as insert 100. Thus, a wall of ICFs with inserts 200 will channel water that penetrates the ICFs down and out of the wall. Because the protuberances 220 are narrow, if there is misalignment of the protuberances between courses of the wall, it is unlikely the misalignments will result in any water being retained in the wall at the top of the protuberances.

FIGS. 11 to 13 illustrate a third embodiment for the inserts. Turning to FIGS. 11 to 13, like insert 200 of FIGS. 8 to 10, insert 300 has a plurality of parallel slots 310 extending from a bottom wall 312 of the panel toward a top wall 314 of the panel and a plurality of protuberances 320 which are rectangular in shape and extend from the bottom wall 312 to the top wall 314 of the insert panel 300. Also as with insert panel 200, with insert panel 300, each slot 310 extends along one protuberance 320 partially bisecting the protuberance. The back face 318 of insert 300 is indistinguishable from the back face of insert 200. However, the protuberances 320 of inserts 300 are wider than those of inserts 200. Nevertheless, insert 300 functions in substantially the same manner as insert 200.

Because the back faces of the inserts lack protuberances, concrete poured into a wall formed of the ICFs with inserts will tightly pack against the back faces of the inserts with less risk of lacunae formation.

In each of the example inserts, the slots are located within the protuberances, where the panel is thickest. This results in a stronger panel than one where the slots are spaced from the protuberances. Further, by locating the slots within the protuberances, water is not channeled into the slots where there may be a risk some water could be trapped by the ties. Nevertheless, inserts where the slots are partially within the protuberances, or spaced from the protuberances, may still assist in reducing the prospect of water damage.

The inserts, in addition to channeling water out of the wall, increase the insulation provided by the wall (i.e., they increase the R-value of the wall). Notably, even if the front face of the inserts lacked protuberances, the inserts would provide a manner of increasing the insulation provided by the wall. Thus, in some embodiments, inserts could be provided with front faces that lack protuberances and are therefore the same as the back face of inserts 100, 200, and 300.

The dimensions of the inserts can be adjusted to adapt the inserts for use with different ICFs.

Although three different shaped protuberances have been described, it will be apparent that insert panels may be provided with other protuberance shapes, sizes, and patterns and still assist in channeling water out from ICFs provided with such insert panels.

The described insert panels can be formed by blow molding foam beads into an appropriately shaped mold with steam to fuse the beads. Alternatively, the inserts may be formed by wire cutting rectangular foam blocks.

Other features and advantages will be apparent to those skilled in the art and, therefore, the invention is defined in the claims. 

1. An insert for an insulated concrete form, comprising: an expanded foam panel having a plurality of parallel slots extending from a bottom wall of said panel toward a top wall of said panel, each slot extending to a front face of said panel and to a back face of said panel, each slot extending a majority of a distance between said bottom wall and said top wall of said panel, said slots spaced and sized to receive ties between opposed panels of an insulated concrete form such that said panel may be inserted between said opposed panels, wherein said front face of said panel has protuberances.
 2. (canceled)
 3. The insert of claim 1 wherein each protuberance extends from said top wall to said bottom wall.
 4. The insert of claim 3 wherein each slot extends along one said protuberance.
 5. The insert of claim 3 wherein each protuberance, proximate said top wall, is radiused.
 6. The insert of claim 5 wherein each protuberance comprises a substantially circular portion extending from said top wall.
 7. The insert of claim 6 wherein said substantially circular portion is a first substantially circular portion and each protuberance further comprises a second substantially circular portion extending from said bottom wall.
 8. The insert of claim 7 wherein each protuberance further includes a narrow neck joining said first substantially circular portion to said second substantially circular portion.
 9. The insert of claim 8 wherein each slot extends along one said protuberance.
 10. The insert of claim 3 wherein each protuberance has a rectangular shape with long sides of said rectangular shape extending from said top wall to said bottom wall of said panel.
 11. The insert of claim 10 wherein each slot extends along one said protuberance.
 12. The insert of claim 2 wherein said back face of said panel is free of protuberances.
 13. The insert of claim 6 wherein said back face of said panel is free of protuberances.
 14. The insert of claim 2 wherein said back face of said panel is, apart from said slots, featureless.
 15. An insulated concrete form comprising: an expanded foam first panel; an expanded foam second panel opposite said first panel; a plurality of ties extending between said first panel and said second panel, each tie having a first head embedded in said first panel and a second head embedded in said second panel; an expanded foam insert panel having a plurality of parallel slots extending from a bottom wall of said insert panel toward a top wall of said insert panel, each slot extending to a front face of said insert panel and to a back face of said insert panel, each slot extending a majority of a distance between said bottom wall and said top wall of said insert panel, said front face of said insert panel having protuberances, said insert panel inserted between said first panel and said second panel with each slot of said insert panel receiving one of said ties and a front face of said insert panel lying adjacent an inside face of said first panel, said protuberances arranged so as to provide spaces between said inside face of said first panel and portions of said insert panel between protuberances for channeling water entering said insulated concrete form from said insulated concrete form.
 16. (canceled)
 17. The insulated concrete form of claim 15 wherein each protuberance extends from said top wall to said bottom wall of said insert panel.
 18. The insulated concrete form of claim 17 wherein each slot of said insert panel extends along one said protuberance.
 19. The insulated concrete form of claim 18 wherein each protuberance comprises a first substantially circular portion extending from said top wall of said insert panel, a second substantially circular portion extending from said bottom wall of said insert panel, and a narrow neck joining said first substantially circular portion to said second substantially circular portion.
 20. The insulated concrete form of claim 18 wherein each protuberance has a rectangular shape with long sides of said rectangular shape extending from said top wall to said bottom wall of said insert panel.
 21. The insulated concrete form of claim 18 wherein said back face of said insert panel is free of protuberances. 